# Patent

## Title
Polygon mast

## Abstract

Aspects of the invention relate to telescoping mast assemblies (telescoping “towers”), polygonal sided masts for use in such assemblies, methods of fabricating polygonal sided masts, methods and apparatus for sequentially actuating and deactuating hold-down and locking mechanisms in telescoping towers, and such other aspects as will be understood from the present descriptions and drawings. Telescopic towers are usable for supporting and raising to a height any type of communications payload, including, for example, radio antennas, television antennas, any type of surveillance and/or sensor payloads, including, for example, microphones, cameras, flood lights, and the like.

## Background
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Patent Application No. 61/000,949 filed Oct. 29, 2007, which is hereby incorporated by reference in its entirety.


FIELD OF THE INVENTION
Aspects of the invention relate to telescoping mast assemblies (telescoping “towers”), polygonal sided masts for use in such assemblies, methods of fabricating polygonal sided masts, methods and apparatus for sequentially actuating and deactuating hold-down and locking mechanisms in telescoping towers, and such other aspects as will be understood from the present descriptions and drawings. Telescopic towers are usable for supporting and raising to a height any type of communications payload, including, for example, radio antennas, television antennas, any type of surveillance and/or sensor payloads, including, for example, microphones, cameras, flood lights, and the like.



BRIEF DESCRIPTION OF THE DRAWINGS
The figures are not to scale.
FIG. 1A is a perspective view of a telescoping tower embodying aspects of the present invention. The tower is shown in its fully-nested condition.
FIG. 1B is a side elevation view of a telescoping tower embodying aspects of the present invention. The tower is shown in its fully-nested condition.
FIG. 1C is a side elevation view of a telescoping tower embodying aspects of the present invention. The tower is shown in its fully-extended condition.
FIG. 2A is a perspective cutaway view of a telescoping tower embodying aspects of the present invention. The tower is shown in its fully-nested condition.
FIG. 2B is an enlarged perspective cutaway view of a top portion of the telescoping tower shown in FIG. 2A.
FIG. 2C is an enlarged perspective cutaway view of a bottom portion of the telescoping tower shown in FIG. 2A.
FIG. 2D is an enlarged side elevation cutaway view of a bottom portion of the telescopic tower shown in FIG. 2A.
FIG. 2E is an enlarged side elevation cutaway view of a top portion of the telescopic tower shown in FIG. 2A.
FIG. 3A is a perspective view of a telescoping interior tube that may be employed in a telescoping tower according to aspects of the present invention. The tube is shown with a portion removed or broken away to reduce space on the drawing. Sections shown in FIGS. 10 and 11 are taken along section lines 10-10 and 11-11.
FIG. 3B is a side elevation view of the broken-away tube of FIG. 3A.
FIG. 3C is a top plan view of the tube of FIG. 3A.
FIG. 3D is a bottom plan view of the tube of FIG. 3A.
FIG. 4 is a perspective view of three nested tubes of a telescopic tower embodying aspects of the present invention. The three tubes may be the three innermost tubes of a telescoping tower such as shown in FIG. 1A.
FIG. 5 is a perspective view of two nested tubes of a telescopic tower embodying aspects of the present invention. The three tubes may be the two outer tubes of the three tubes shown in FIG. 4.
FIG. 6A is an exploded perspective view showing the elements of a hold-down mechanism aspect of the present invention.
FIG. 6B is a perspective view showing the elements of the hold-down mechanism of FIG. 6A in an assembled and operating position. The tubes on which the elements are mounted are not shown in this view for clarity.
FIG. 7A is an exploded perspective view showing the elements of a locking mechanism aspect of the present invention.
FIG. 7B is a perspective view showing the elements of the locking mechanism of FIG. 7A in an assembled and operating position. The tubes on which the elements are mounted are not shown in this view for clarity.
FIGS. 8A-8Q and companion FIGS. 9A-9Q (i.e., FIG. 8A is a companion of FIG. 9A, etc.) are cut-away side-elevation views showing the sequence of operation of the hold-down and locking mechanisms as three adjacent tubes in a tower embodying aspects of the present invention are extended and retracted. Each cut-away side-elevation view is at ninety degrees to its companion so that the respective companion views are cut through the locking mechanism elements (FIGS. 8A-Q) and through the hold-down mechanism elements (FIGS. 9A-Q).
FIGS. 10A-10K and companion FIGS. 11A-11K are also companions to FIGS. 8A-8K and 9A-9K (i.e., FIG. 10A is a companion of FIG. 1A and of FIGS. 8A and 9A, etc.) are cut-away side-elevation views of both the upper and lower portions of a tower showing the sequence of operation of the hold-down and locking mechanisms as three adjacent tubes in a tower embodying aspects of the present invention are extended and retracted. Each cut-away side-elevation view is at ninety degrees to its companion so that the respective companion views are cut through the locking mechanism elements (FIGS. 10A-K) and through the hold-down mechanism elements (FIGS. 11A-K).
FIG. 12A is a perspective cross section of the drive nut assembly for a telescoping tube.
FIG. 12B is an exploded view of the major elements of the drive nut assembly of FIG. 12A.
FIG. 12C is a side elevational cross sectional view of the drive nut assembly of FIGS. 12A and 12B.
FIG. 12D is a side elevational cross sectional view of a variation of the drive nut assembly of FIGS. 12A and 12B.
FIG. 13A a cut-away top plan view of the drive gear box portion of a telescoping tower according to aspects of the present invention.
FIG. 13B is a side elevation cross section along the sections lines 13B of FIG. 13A.
FIG. 13C is a side elevation cross section along the sections lines 13C of FIG. 1A.
FIG. 14 is a perspective view of a portion of a polygonal tube according to aspects of the invention, which tube is useful as a tube in a telescoping tower
FIG. 15 is a top plan view of the polygonal tube portion of FIG. 14.
FIG. 16A is a top plan view showing a way in which a polygonal tube portion may be formed from a flat rectangular sheet of metal.
FIG. 16B is a top plan view showing the manner in which two portions of polygonal tube as in FIGS. 12 and 13 may be joined together to form a polygonal tube.
FIG. 17 show steps in making a faceted cylinder (polygonal tube) in accordance with aspects of the present invention.



DESCRIPTION OF THE INVENTION
Turning now to the drawings in which like reference characters identify the same elements in several views, FIGS. 1A, 1B and 1C show a telescoping mast assembly (telescoping “tower”) 10 embodying various aspects of the present invention. In FIGS. 1A and 1B, the telescoping mast assembly 10 is shown in its fully “nested” condition—each of the multiple mast sections (“tubes”) 11-18 of the assembly 10 is in its fully retracted position. In FIG. 1C, the telescoping mast assembly is shown in its fully extended position—each of the multiple mast sections 11-18 of the assembly 10 is fully extended. An axial drive screw mechanism (not seen in FIGS. 1A-1C) drives the extension and retraction of the tubes in a predetermined self-actuated sequence. The drive screw mechanism has a drive screw controllably rotated in either of two directions by a gear train (not shown in FIGS. 1A-1C) within a gear box 19, powered by a drive motor 20 or, alternatively, powered manually by a hand crank (not shown) that engages a hand crank receptacle 21. The gear box 19 also functions as a base for the telescoping mast assembly 10 that may be affixed to a fixed or movable support. Gear box 19 includes an anti-backdrive brake that facilitates stopping an extension of the tower sections at any point and that obviates the need to lock that last inner section to the outer section when the tower is raised to its maximum extension.
One aspect of the present invention is the use of cylindrical tubular mast sections having a polygonal cross section rather than a circular cross section. Although the various figures herein show such polygonal mast sections, it will be understood that certain aspects of the invention are not limited to mast sections having a polygonal cross section. Although a deca-hexagonal (16 sided) polygon cross section is employed in various examples herein because it closely approximates the wind characteristics of a circular cross section mast section, other sided polygons may be employed. Whether polygonal or circular in cross section, the tube sections are close fitting and progressively smaller in diameter. In practical implementations, the tubes may each have, for example, lengths in the order of five to twelve feet.
The top of each of all but the top one of the mast sections of FIGS. 1A-1C is shown encircled and capped by a respective annular assembly 22-28 that includes elements of mast section hold-down and mast section locking assemblies as are described in detail below. Hold-down assemblies prevent premature extension of mast sections. Lock assemblies positively lock the mast against retraction as each section is fully extended. The hold-down assemblies and lock assemblies according to aspects of the present invention are configured to cause a self-sequencing in which the hold-down and locking operations are performed separately and sequentially so as to assure proper extension and retraction of the mast sections.
Refer now to a cutaway view of the nested mast sections as shown in FIG. 2A and enlarged details thereof in FIGS. 2B-2E. A drive screw 30 is shown extending upward from the gear box 19 through the nested mast sections to a point near the top of the innermost mast section. An annular support assembly 31 (best seen in FIGS. 2B and 2E) affixed to near the top of the innermost mast section provides support for the top of the drive screw, particular during shipment. Each of the inner mast sections has a respective drive nut assembly 32-38 (best seen in FIGS. 2C, 2D, and 12A-D).
The drive screw 30 is threaded along its length except at a bottom portion 30a (best seen in FIG. 2D—the slightly narrowed diameter of the drive screw) and a top portion (best seen in FIG. 2B—the slightly narrowed diameter of the drive screw) 30b. Threads are shown in FIGS. 8A-Q, 9A-Q, 10A-K and 11A-K. In the nested condition, only one drive nut assembly, that of the innermost mast section, is on the threads of the drive screw.
The drive screw may have a one inch lead with ten individual starts and may employ an acme thread. A nut going on or coming off the drive screws thus has ten possibilities for each rotation: ten within a tenth of an inch. There is a 100/1000th inch linear travel from one lead to another. All of the nuts are spring loaded with an allowance of about 125/1000th inch. The springs work in both an upward and downward direction. Nuts have a cone shape and the end of the top end of the drive screw has a semi-spherical end to facilitate a nut coming onto the drive screw.
FIG. 2A shows a bracket 39 for affixing the telescoping mast assembly 10 to a structure, such as a building. Also seen in FIG. 2A is an enclosure 40 for control circuitry for turning the drive motor on and off and for selecting the direction in which it rotates. FIG. 2A also shows an upper optical limit assembly 41 (best seen in FIG. 2D) for detecting full extension of the mast sections and a lower optical limit assembly 42 (best seen in FIG. 2C) for detecting full retraction of the mast sections. Each optical limit assembly includes a housing 41a (42a), a combination light source and sensor 41b (42b), a series of holes 41c through the seven outermost mast sections (not seen in the FIG. 2C view) and a mirror in the innermost mast section (not seen in the FIG. 2C view), aligned with the series of holes. When the mast sections are fully nested, optical limit assembly 41 detects the fully nested condition and provides a signal that is used to turn off the motor in order to stop the drive screw. Similarly, when the mast sections are fully extended, assembly optical limit assembly 42 detects the fully extended condition and provides a signal that is used to turn off the motor in order to stop the drive screw. Of course, the motor may be manually turned off at any time in order to place the telescoping mast assembly in a condition somewhere between fully nested and fully extended. Alternatively or in addition, automatic turn off of the motor may also be accomplished by counting revolutions of the drive screw. Fail safe mechanical stops may also be provided to provide a forced mechanical stop of extension or retraction in the event that the automatic sensing malfunctions.
FIGS. 2B and 2E show the ring assemblies 22-28 in greater detail. The ring assemblies each include in their annular encircling portions elements of multiple hold-down assemblies and elements of multiple lock assemblies. In addition, each ring assembly includes an upper flange cap that caps the respective mast section. The various hold-down and lock assemblies and flange caps are staggered in their angular orientation in order to sequentially operate as is explained below. Details of the hold-down assemblies and locks and their operation as the telescopic mast assembly is extended and retracted are set forth below.
Although FIGS. 1A-C and 2A-E show eight mast sections, polygonal and circular cross-sectioned mast sections in accordance with aspects of the invention may, in principle, be used in telescopic mast assemblies with more than eight and as few as three mast sections. For simplicity in explanation, hold-down and locking mechanism aspects of the present invention will be described with examples employing three mast sections, it being understood that the same principles apply to telescopic mast assemblies employing more than three mast sections by applying the teachings to consecutive triads of mast sections.
FIGS. 3A-3D show an example of an intermediate (middle) mast section 50 of a mast section triad (the three masts may be all or some of the masts of a telescopic mast assembly). The mast section may be a generally-cylindrically-shaped polygon tube formed from two halves 50a and 50b fastened together at overlaps 51a and 51b with rivets 52 or some other suitable securing method. A deca-hexagon (16 sided) polygon mast is shown in this example. Low friction pads or slides 53 are shown around the bottom periphery for spacing the mast section 50 from the slightly larger mast section (not shown) in which it nests and extends and for facilitating the relative movement of those adjoining mast sections. Similarly, low friction pads or slides 54 are located around the inside of the top of mast section 50 for the same reasons with respect to the slightly smaller mast section (not shown) that nests and extends within mast section 50. A hole 55 for cooperating with an optical limit switch is provided in the wall of the mast section 50.
Elements of two hold-down mechanisms and two lock mechanisms are shown in FIGS. 3A-3D. As will be explained below, each hold-down mechanism and each lock mechanism employs three main elements, each located on one of three consecutive mast sections (a triad of mast sections). The elements of a hold-down mechanism and a lock mechanism in accordance with aspects of the present invention will be described in greater detail below, as will their operation. Two hold-down actuator pads 56 and 57 are seen in FIGS. 3A and 3B. Each is secured to the outer wall of the mast section. Two lock actuator pads 58 and 59 are also affixed to the outer wall of the mast section 50. The mast section annular encircling portion of a ring assembly 60 at the top of mast section 50 holds a pair of hold-down housings 61 and 62, from each of which extends through a respective slot in the wall of the mast section 50 a portion of the hold-down housing from which a pivoting hold-down extends. The mast section annular encircling portion of ring assembly 60 also holds a pair of lock housings 63 and 64, from each of which extends through a respective slot in the wall of the mast section 50 a portion of the lock housing from which a pivoting lock extends.
Nut assemblies 66 of FIGS. 3A-3D are described below in connection with FIGS. 12A-D.
Depending on the number of mast sections in a telescopic mast assembly, each mast section may have two hold-downs and two locks or two hold-downs and four locks (four locks may be used, for example, for the lower mast sections that must support a higher load than higher, smaller mast sections). As in the example of FIGS. 3A-3D, locks and hold-downs should be spaced apart from each other and alternated to the extent possible, such as having the pairs of hold-downs and locks opposite each other and spaced by 90 degrees.
FIG. 4 shows three consecutive mast sections (a triad) nested. In this example, an inner mast section 70 is shown nested within an intermediate mast section 72 which is, in turn, nested within an outer mast section 74. The main portion of intermediate mast 72 is hidden in this figure (see FIG. 5). The outer mast may be further nested within another mast section (not shown). Inner mast section 70 has no top ring assembly. However, the top ring assemblies of mast sections 72 and 74 are shown. The top ring assembly of intermediate mast section 72 has an upper flange cap 76 which is fastened, as by screws passing through screw holes 78, to the annular encircling portion of the top ring assembly, which is, in turn, fastened to the top portion of mast section 72 in a suitable way such as by rivets 80. The upper flange cap 76 has slotted tongues into each of which a lock may extend and into each of which an upper beak portion of a hold-down actuator pad may extend so that shoulders of the hold-down actuator pad engage the upper flange cap to cause the mast section to extend in order that the mast section picks up the drive shaft with its nut. This operation is explained further below. FIG. 4 also shows a hold-down housing 82 on mast section 72, a hold-down post 84 on mast section 74, lock housings 86 and 88 on mast section 72, lock posts 90 and 92 on mast section 74, a lock housing 94 and a hold-down housing 96 on mast section 74.
FIG. 5 shows the outer two mast sections of the FIG. 4 depiction—the innermost mast section 70 is not present. The upper flange cap 76 is also not present. The view of FIG. 5 reveals the intermediate mast section 72 and a second hold-down housing 82a. 
FIG. 6A shows the elements of a hold-down assembly in accordance with aspects of the present invention. The hold-down assembly includes a hold-down housing 102, a pin 104 that functions as a spring rest, a hold-down 106 that is rotatably held within housing 102 and which rotates on the axis of its pin 108, first and second springs 110 and 112, a hold-down actuator pad 114 and a hold-down post 116. FIG. 6B shows the hold-down assembly elements in an operating position. Pin 104 passes through a hole 106a in the hold-down 106 and the holes 102a in the hold-down housing 102, allowing the hold-down to rotate along the axis of pin 104. Springs 110 and 112, working against spring rest pin 108, urge the hold-down into its engaged position as shown in FIG. 6B. Hold-down 106 has an extending hook portion 106b that engages a mating hook 116a extending from the hold-down post 116. The hold-down actuator pad has an upward extending “beak” or lip portion 114a having a beveled top portion 114b. When the hold-down actuator pad 114 moves upward with respect to the hold-down 106, its upper beak or lip engages the upper lip 106c of the hold-down 106, causing it to rotate clockwise and disengage the mating hooks 106b and 116a. The lower lip 106d of the hold-down is engaged by the beak or lip portion 114a of the hold-down actuator pad when it moves downward with respect to the hold-down. With respect to three consecutive mast sections, the hold-down actuator pad 114 is carried by the innermost mast section, the hold-down housing 102 (carrying the hold-down 106) by the intermediate mast section, and the hold-down post 116 by the outer mast section. In the hold-down engaged condition shown in FIG. 6B, the intermediate mast section cannot be extended with respect to the outer mast section. The operation of the hold-down assembly is explained in further detail below.
FIG. 7A shows the elements of a lock assembly in accordance with aspects of the present invention. The lock assembly includes a lock pad 120, a lock housing 122, a pivot pin 124, a lock 126, first and second springs 128 and 130, and a lock actuator post 132. The lock 126 has a pin 134 that functions both as a spring retainer and a lock stop. FIG. 7B shows the hold-down assembly elements in an operating position. Pivot pin 124 passes through a hole 126a in the lock 126 and the holes 122a in the hold-down housing 122, allowing the lock to rotate along the axis of pin 124. Springs 128 and 130, working against spring rest pin 134, urge the lock into its locked position as shown in FIG. 7B. Lock 126 has an extending latch portion 126b that engages the bottom side of the lock pad 120. The lock actuator post has an upward extending U-shaped member 132a having a slot 132b that engages lock stop pin 134 of the rotating lock. When the pin is at the bottom of the slot, the lock is open; when the pin is at the top of the slot, the lock is locked. With respect to three consecutive mast sections, the lock pad 120 is carried by the innermost mast section, the lock housing 122 (carrying the lock 126) by the intermediate mast section, and the lock actuator post 132 by the outer mast section. The slot in the lock actuator post forces the lock into position even though the lock is spring loaded in the locking position. This results in a positive locking operation. In the locked condition shown in FIG. 7B, the inner mast section cannot be retracted with respect to the intermediate mast section. The operation of the hold-down assembly is explained in further detail below.
The following table describes further the operation of the hold-down and locking mechanisms with respect to extension and retraction of the tower sections.













FIGS.
Steps
Narrative
Status







FIGS. 1A, 1B, 2A,
Starting condition.
Tubes fully retracted
Hold-downs


2B, 2C, 2D, 2E, 8A,
Tower fully nested.
as determined by
engaged


9A, 10A and 11A.

electrical stop or by
Locks unlocked




fail-safe mechanical
Inner tube's nut




stop. Only one nut
on lead screw




(inner tube's nut) is




on the lead screw; the




other nuts are on the




lower unthreaded




portion of the lead




screw. All hold-




downs are engaged




(the outermost tube




has no hold-down - it




is secured to the




tower base. All locks




are unlocked




(allowing inner tube




to move vis-à-vis the




intermediate tube).




Top of lead screw is




supported by a lead




screw-supporting




member 31 (FIGS.




2B, 2E).



Extension of inner
Drive motor rotates
Inner tube extends



tube begins.
lead screw in
out of




direction that causes
intermediate tube




the inner tube to




extend out of the




intermediate tube that




is held down to the




outer tube by the




hold-down




mechanisms. The




locking mechanisms




are not locked.


FIGS. 8B, 9B, 10B
Inner tube nears its
Hold-downs remain


and 11B.
full extension.
actuated, keeping the




intermediate tube




from moving. Locks




remain unlocked.




Hold-down actuator




pads approach hold-




downs. Lock pads




approach lock.


FIGS. 8C, 9C, 10C
Inner tube continues
Hold-downs remain


and 11C.
upward toward its
actuated, keeping the



full extension.
intermediate tube




from moving. Locks




remain unlocked.




Hold-down actuator




pads more closely




approach hold-downs.




Lock pads are passing




lock.


FIGS. 8D, 9D, 10C
Inner tube continues
Hold-downs remain


and 11C.
further upward
actuated, keeping the



toward its full
intermediate tube



extension.
from moving. Locks




remain unlocked.




Hold-down actuator




pads begins to engage




the hold-downs




(upper lip of hold-




downs). Lock pads




continue to pass lock.


FIGS. 8E, 9E, 10E
Inner tube continues
Hold-downs remain


and 11E.
further upward
actuated, keeping the



toward its full
intermediate tube



extension.
from moving. Locks




remain unlocked.




Hold-down actuator




pads begin to rotate




the hold-downs




toward




disengagement. Lock




pads continue to pass




by the lock.


FIGS. 8F, 9F, 10F
As inner tube
Hold-downs
Hold-downs


and 11F
continues further
disengage, allowing
disengaged



upward toward its
the intermediate tube
Stops engaged



full extension, the
to move with respect
Intermediate tube



hold-downs
to the outer tube (top
extends out of



disengage and stops
lip of the hold-down
outer tube along



on the intermediate
actuator on inner tube
with inner tube



tube are engaged so
engages the hold-



that the intermediate
down on the



tube is carried by the
intermediate tube,



inner tube.
causing it to release




from the hold-down




post hook on the




outer tube). As the




hold-down clears the




hold-down post hook,




the shoulders of the




hold-down actuator




pads engage the stop




provided by the upper




flange cap. The inner




tube carries the




intermediate tube




along with it (the




inner tube's nut is




still on the lead




screw; the




intermediate tube's




nut is not yet on the




lead screw). The




locks remain




unlocked. Lock pads




are now above the




lock so that the lock




can be rotated in




order to engage the




bottom of the lock




pad (it is not yet




rotated). The overlap




between the inner and




intermediate tube is




determined by the




relative locations of




the hold-down pads




and the lock pads.


FIGS. 8G, 9G, 10G
As inner tube
Because the outer
Locks begin to


and 11G.
continues further
tube cannot move (if
engage



upward, carrying the
it is the ultimate outer



intermediate tube
tube, it is fixed to the



with it, the locks
base, otherwise it is



begin to engage.
held down by hold-




down mechanisms),




the lock pin on the




lock rides up in the




lock post slot (carried




by the outer tube) as




the intermediate tube




extends (it is carried




up by the inner tube's




engagement of the




stop), causing the




lock to begin rotating




under the lock pad.


FIGS. 8H, 9H, 10G
The inner tube
The lock pin on the
Locks fully


and 11G.
continues further
lock rides up in the
engaged



upward, carrying the
lock post slot to the



intermediate tube
top of the slot,



with it. The locks
rotating the lock into



fully engage into
its fully engaged



their locked positions
locked position under



(but there is still a
the lock pads (the



gap).
intermediate tube is




still carried by the




inner tube-there is a




slight gap between




the lock and the




bottom of the lock




pad; the intermediate




tube's nut is not yet




on the lead screw). In




its fully rotated




position, the lock also




engages a lock stop in




the lock housing.


FIGS. 8I, 9I, 10I
Intermediate tube's
The inner and
Both nuts on the


and 11I.
nut goes on lead
intermediate tubes
lead screw (inner



screw
continue upward
and intermediate)




together (the




intermediate tube is




carried by the inner




tube) causing the




intermediate tube's




nut to engage a thread




on the lead screw.




The upper movement




of the intermediate




tube causes the




intermediate tube's




nut to engage the lead




screw, maintaining




the position of the




lock pad constant




with respect to the




lock housing as the




inner tube and




intermediate tube




move upward (the




nuts of both tubes are




on a lead screw




thread).


FIGS. 10J and 11J
Inner tube's nut
The inner and
Inner tube's nut



comes off lead screw
intermediate tubes
goes off top of



threads
continue upward
threaded portion




together (the
of lead screw; gap




intermediate tube's
between lock and




and inner tube's nuts
bottom of lock




are both on the lead
pad goes away;




screw) causing the
intermediate nut is




inner tube's nut to go
on the lead screw.




off the threads at the
Intermediate




top of the lead screw.
tube's nut is on




The inner tube then
the lead screw.




seats on the lock of




the intermediate tube,




causing the gap to go




away. The inner tube




then goes up along




with the intermediate




tube.


FIGS. 10K and
Inner tube's nut
As the inner tube
Inner tube's nut


11K.
comes off lead screw
continues upward
goes off top of



completely
along with the
lead screw




intermediate tube, it
completely




eventually goes off
Intermediate




the top of the lead
tube's nut remains




screw completely (the
on the lead screw.




topmost portion of the




lead screw is




unthreaded). As the




intermediate tube




extends it reaches the




next set of hold-down




mechanisms and lock




mechanisms and the




cycle repeats. Note




however that the




intermediate tube is




not locked to the




bottom outer tube




when there is only




one three tube triad -




the next to the outside




tube always has its




nut on a thread when




the tower is fully




extended and that is




sufficient without




otherwise locking that




tube section.



Begin retraction
Rotate lead screw in
Intermediate



Inner tube's nut
direction to cause
tube's nut is on



comes onto lead
intermediate tube to
the lead screw.



screw.
retract. The inner
Inner tube's nut




tube, resting on the
comes onto the




locks, moves along
lead screw.




with the intermediate




tube and the inner




tube's nut engages a




thread on the top of




the lead screw.



Intermediate tube's
The inner tube and
Intermediate



nut comes off the
intermediate tube
tube's nut comes



lead screw
continue to retract
off the lead screw.




together. The nut of
Inner tube's nut is




the lower tube, the
on lead screw,




intermediate tube
unloading the




comes off the lead
locks. Gap




screw threads,
reappears.




shifting the load of




the lower tube to the




shoulders of the hold-




down actuator pads




that are engaging the




upper flange cap.




The inner tube's nut




remains on the lead




screw, taking the load




of both tubes and




unloading the locks.


FIGS. 8J and 9J
Begin unlocking
The inner and
Lock pin enters



sequence
intermediate tubes
lock post slot.




continue to move




together. The lock




pin enters the lock




post slot (carried by




the non-moving outer




tube).


FIGS. 8K and 9K
Continue unlocking
The inner and
Lock pin



sequence
intermediate tubes
continues along




continue to move
slot, rotating lock.




together. The lock




pin continues through




the lock post slot




causing rotation of




the lock.


FIGS. 9L and 9L
Unlocking sequence
The inner and
Lock pin reaches



completed.
intermediate tubes
bottom of slot;




continue to move
lock is unlocked.




together. The lock




pin continues to the




bottom of the lock




post slot causing full




rotation of the lock,




opening the lock.




Note that the relative




locations of the lock




pads/locks and hold-




down pads/hold-




downs does not




change through FIGS.




8I/9I through 8K/9K




because the




intermediate tube is




hanging from the




inner tube.


FIGS. 2A, 2B
Intermediate tube
Inner tube moves



reaches its nested
down while



position
intermediate tube




remains stationary its




nested position


FIGS. 8M and 9M
Begin hold-down
Beak of hold-down



activation sequence
actuator pad engages




lower lip of hold-




down, beginning to




rotate it.


FIGS. 8N and 9N
Continue hold-down
Jaws of hold-down



activation sequence
begin to engage hook




of hold-down post.


FIGS. 8O and 9O
Hold-down
Beak of hold-down
Hold-down



activation sequence
actuator pad pushes
engaged.



completed.
lower lip of hold-




down to fully engage




hook of hold-down




post


FIGS. 8P and 9P

Lock pads and hold-




down actuator pads




below the respective




locks and hold-




downs. Inner tube




continues retraction.


FIGS. 8Q and 9Q
Return to fully
All tubes fully nested
Hold-downs



nested condition.

engaged, locks





unlocked.









FIGS. 12A-12C show a nut assembly 32-38 (FIGS. 2C, 2D) in greater detail. FIG. 12D shows a variation on the nut assembly of FIGS. 12A-12C. Referring first to the nut assembly of FIGS. 12A-12C, a flange 140 adapted for attachment to a tube section has a base 142 having screw holes 142a and an annular neck portion 144 for captively holding a threaded drive nut 146, a wavy ring-shaped metal spring 148, a retaining ring 150 and a snap ring 152. The drive nut 152 has a collar 154 for cooperating with the retaining ring and snap ring to capture the wavy spring. Collar 154 has a gap to allow a pin 156 to interfere with the free rotation of the drive nut within the flange. The wavy spring's vertical “play” and the collar gap's slight rotational “play” permit the nut to more readily engage the threaded drive screw.
Referring now to the variation shown in FIG. 12D, an elastomer (a natural or synthetic rubber), preferably moldable or castable, such as polyurethane or some other suitable material is used instead of a wavy metal washer is employed. The springiness of the polyurethane provides not only vertical and rotational “play” but also provides some cushioning as mast sections are retracted. One way to implement such an arrangement is to provide a ribbed surface area inside the flange collar 144 onto which a castable elastomer such as polyurethane is cast in place. The polyurethane contacts the captive nut and a slight gap is provided between the nut and the flange collar to as to allow some movement of the nut. A metal washer underneath the polyurethane prevents wear of the polyurethane with respect to a retaining ring 160.
Suitable materials other than an elastomer may include other thermoset plastics, carbon-fiber and carbon-fiber impregnated thermoset plastics, fiberglass and fiberglass impregnated thermosets, cork, or composites of some or all of the materials mentioned in this paragraph.
FIG. 13A is a plan view of the gear box 19 with its cover removed.
FIG. 13B is a cross sectional view along section lines 13B-13B of FIG. 13A.
FIG. 13C is a cross sectional view along section lines 13C-13C of FIG. 13A.
A polygon mast according to aspects of the present invention may be fabricated from metal sheets, for example aluminum sheet or stainless steel sheet. The sections can be manufactured from nearly any material that is available in sheets that can be formed, including, for example, aluminum, stainless steel, galvanized steel, and any other suitable material. One may start with a flat metal sheet. Such sheets commonly have a width of 96 inches and a length of as much as 14 feet. A 100 foot tower may employ 14 foot mast sections. Shorter sheets and shorter sections may be employed depending on the desired product height. Automated computer numerically controlled (CNC) may be employed to punch holes, cut slots, etc. in a sheet prior to forming into a “half shell” 170 such as shown in FIGS. 14 and 15. The polygonal mast may be formed from more than two pieces. A single piece cannot be easily fabricated.
A flat sheet may be formed into a half shell by applying a series of bends along its length, such as 22.5 degree bends when a sixteen-sided mast cylinder is desired. The bends may be applied in any suitable way to a metal sheet 171 using either manually-controlled or computer-controlled devices. FIG. 16A shows the application of such bends using an elongated two-piece die punch 172a, 172b. A stop 173 may be used for aligning the metal sheet with the die. FIG. 16B shows two half shells 170a and 170b mated and fastened together along two overlapping seams 174a and 174b. Rivets or other suitable fasteners may be employed. The end of each of the half shells 170a and 170b may be offset as shown in order to facilitate the overlap and securing together of the half shells.
An example of steps useful for fabricating a polygonal mast section is shown in FIG. 17.
Polygon mast section “shells” may also be formed from thermoset plastics or from composites by any of various suitable methods, including, for example, pultrusion, filament winding or layup (using fiberglass or carbon fiber, for example) over a mandrill. Shells formed in any of such manners may provide excellent strength to weight ratios.
Whether the polygonal sections are formed from metal or other material, as shown in the examples of FIGS. 3A and 3B, for example, corners of the polygon may be used to hold slides and/or to mount elements of the hold-down or locking mechanisms.
Polygon mast sections according the teaching herein may be fabricated with very tight clearances, for example as little as 5 to 6/1000 inch. Such tolerances result in a very “tight” tower.
Although aspects of the invention are not limited to a mast having the cross section of a sixteen-sided polygon, that number of sides is useful because the resulting wind coefficient of the tower is essentially the same as that formed from mast sections having a circular cross section.
The manufacture of polygonal masts and towers has several advantages. Generic metal sheets can be stocked, usable for various different mast and tower configurations. In addition, manufacturing lead time is very short—there is no need to extrude aluminum parts, for example.
INCORPORATION BY REFERENCE
U.S. Pat. No. 5,163,650 is hereby incorporated by reference in its entirety.

## Claims

1. A telescoping mast assembly comprising:
three nestable telescoping mast sections, an inner mast section, an intermediate mast section, and an outer mast section, the telescoping mast sections having hold-down and locking mechanisms;
each hold-down mechanism including a hold-down actuator pad disposed on an outside surface of the inner mast section at a first vertical position and a first angular position, a first hook pivotally mounted proximate to the top of the intermediate mast section at the first angular position, and a hold-down post including a second hook fixedly mounted proximate to the top of the outer mast section at the first angular position, the first hook biased to engage the fixed hook when the inner mast section is nested within the intermediate mast section below a hold-down position, the hold-down actuator pad engaging and pivoting the first hook to release the first hook from the fixed hook when the inner mast section is nested within the intermediate mast section above the hold-down position; and
each locking mechanism including a lock pad disposed on the outside surface of the inner mast section at a second vertical position lower than the first vertical position and at a second angular position displaced from the first angular position, a lock member pivotally mounted proximate to the top of the intermediate mast section, and a pivot actuator mounted proximate to the top of the outer mast section, the pivot actuator pivoting the lock member to engage a bottom edge of the lock pad when the inner mast section is nested within the intermediate mast section above a lock position higher than the hold-down position, and pivoting the lock member to disengage the bottom edge of the lock pad when the inner mast section is nested within the intermediate mast section below the lock position.

2. The telescoping mast assembly according to claim 1 wherein the nestable telescoping mast sections have a polygonal cross-section.

3. The telescoping mast assembly according to claim 2 wherein each of the mast sections comprises multiple subsections.

4. The telescoping mast assembly according to claim 3 wherein each of the subsections is fabricated from a flat sheet material.

5. The telescopic mast assembly according to claim 4 wherein the flat sheet material is metal.

6. The telescoping mast assembly according to claim 3 wherein the telescoping mast sections are formed from two half shells.

7. The telescoping mast assembly of claim 1 further including:
a base to which the outer mast section is mounted;
a drive screw extending upward from the base, the drive screw including an unthreaded bottom portion, and a threaded portion located above the bottom portion, the bottom portion having a diameter less than a diameter of the threaded portion;
a drive nut assembly mounted at the bottom of each of the inner mast section and the intermediate mast section, the drive nut assembly of the inner mast section engaging the threaded portion of the drive screw when the inner mast section, the intermediate mast section, and the outer mast section are in a fully nested configuration, the drive nut assembly of the intermediate mast section is positioned around the bottom portion of the drive screw when the inner mast section, the intermediate mast section, and the outer mast section are in a fully nested configuration;
wherein the drive nut assembly of the intermediate mast section engages the threaded portion of the drive screw when the inner mast section is extended within the intermediate mast section an engagement distance above a position where the bottom edge of the lock pad of the inner mast section is engaged by the lock of the intermediate mast section; and
wherein the drive nut assembly of the inner mast section disengages from an upper end of the threaded portion of the drive screw when the inner mast section extends within the intermediate mast section a disengagement distance above the position where the drive nut assembly of the intermediate mast section engages the threaded portion of the drive screw.

8. The telescoping mast assembly of claim 7 wherein the drive screw is coupled to a source of driving force to rotate the drive screw in a first direction to extend the inner mast section, the intermediate mast section, and the outer mast section, and in a second direction to nest the inner mast section, the intermediate mast section, and the outer mast section.

9. The telescoping mast assembly of claim 8 wherein the source of driving force is a motor.

10. The telescoping mast assembly of claim 9 further including:
a lower-limit light source and a lower-limit light sensor disposed on the outer mast section;
a lower-limit mirror disposed inside the inner mast section;
the inner mast section, the intermediate mast section, and the outer mast section each including lower-limit alignment holes formed therein, the lower-limit light source, lower-limit mirror, lower-limit light sensor, and the lower-limit alignment holes positioned to be in optical alignment to form an optical path including the light source, the lower-limit mirror and the lower-limit sensor when the inner mast section, the intermediate mast section, and the outer mast section are in a fully nested configuration; and
wherein the lower-limit sensor is coupled to the motor to turn off the motor when the inner mast section, the intermediate mast section, and the outer mast section are in the fully nested configuration.

11. The telescoping mast assembly of claim 9 further including:
an upper-limit light source and an upper-limit light sensor disposed on the outer mast section;
an upper limit mirror disposed inside the inner mast section;
the inner mast section and the outer mast section each including upper-limit alignment holes formed therein, the upper-limit light source, upper-limit mirror, upper-limit light sensor, and the upper-limit alignment holes positioned to be in optical alignment to form an optical path including the upper-limit light source, the upper-limit mirror and the upper-limit sensor when the inner mast section, the intermediate mast section, and the outer mast section are in a fully extended configuration; and
wherein the upper-limit sensor is coupled to the motor to turn off the motor when the inner mast section, the intermediate mast section, and the outer mast section are in the fully extended configuration.

12. The telescoping mast assembly of claim 7 wherein the threaded portion of the drive screw has multiple individual starts.

13. The telescoping mast assembly of claim 7 wherein the threaded portion of the drive screw employs an acme thread.

14. The telescoping mast assembly of claim 7 wherein the drive screw has a tapered upper end above an end of the threaded portion of the drive screw to guide descending drive nut assemblies onto the drive screw.

15. The telescoping mast assembly of claim 7 wherein the drive nut assemblies of the inner mast section and the intermediate mast section are resiliently mounted to their respective mast sections to provide vertical play in both an upward and downward direction.

16. The telescoping mast assembly of claim 7 wherein the drive nut assemblies of the inner mast section and the intermediate mast section have cone shaped threads at each end thereof.

17. The telescoping mast assembly of claim 1 further including a lower optical limit sensor including:
a lower-limit light source and a lower-limit light sensor disposed on the outer mast section;
a lower-limit mirror disposed inside the inner mast section; and
the inner mast section, the intermediate mast section, and the outer mast section each including lower-limit alignment holes formed therein, the lower-limit light source, lower-limit mirror, lower-limit light sensor, and the lower-limit alignment holes positioned to be in optical alignment to form an optical path including the light source, the lower-limit mirror and the lower-limit sensor when the inner mast section, the intermediate mast section, and the outer mast section are in a fully nested configuration.

18. The telescoping mast assembly of claim 1 further including an upper optical limit sensor including:
an upper-limit light source and an upper-limit light sensor disposed on the outer mast section;
an upper limit mirror disposed inside the inner mast section; and
the inner mast section and the outer mast section each including upper-limit alignment holes formed therein, the upper-limit light source, upper-limit mirror, upper-limit light sensor, and the upper-limit alignment holes positioned to be in optical alignment to form an optical path including the upper-limit light source, the upper-limit mirror and the upper-limit sensor when the inner mast section, the intermediate mast section, and the outer mast section are in a fully extended configuration.